Following the effective training of SDP and A-SDP to the Supervisors and Assistant Supervisors, the next task was to implement and improve efficiency on the shop floor. The Supervisors and Assistant Supervisors encountered several difficulties as they descended to the base to boost output — and one of the most significant difficulties came from the Operators themselves.
On the floor, successful implementation requires the operator's active participation and understanding. Therefore, a unique operator course — Pro Skill (PASTA Workshop) — was designed after understanding the difficulties in implementation. Methods discussed with the OGTC and factory teams how to achieve the same training objective for Operator Training.
The Course: A 3-Hour Intensive Programme
Methods designed a three-hour-long intensive training course for the operators, focused on seven key areas:
PASTA — The Standardisation Tool
PASTA is one of the key instruments for unburdening operators while standardising processes across the entire firm. Most people think standardisation is difficult in the garment industry because it is labour-intensive. For example, if one operator completes an operation at 80% efficiency, another operator may not be able to replicate it — because of inconsistency in the process. To address this, Methods created PASTA.
| P — Pick Up | A — Align | S — Sew | T — Trim | A — Aside |
|---|---|---|---|---|
| As close as possible to needle | As minimum as possible | As long as possible | As automatic as possible | As convenient as possible to the next operator |
| As simultaneous as possible | E.g. 30 cm straight line without stop | Suction cutter | Use work aid for automatic disposal | |
| Fixed blade for overlock | Dispose by sliding | |||
| Cut thread with trimmer in hand |
Workplace Layout
Having a suitable workplace layout is vital. Most often, handling gets worse because of improper workplace design. Through this module, Methods taught operators how to arrange and dispose of parts to reduce time — using practical examples from their own workstations.
Needle Running Time: The Only Time We Make Money Is When the Needle Moves
The only time a factory makes money is when the needle moves. Through this module, Methods helped operators understand the compounding impact of even small delays — if an operator is late for 5 minutes, what is the effect on the entire day, the week, the month? Once operators understand the value of every minute, their relationship with time fundamentally changes.
5S
In this module, operators learned how to implement basic 5S on their workstations — Sort, Set in order, Shine, Standardise, and Sustain. Sample images of before-and-after workstations were shown, making the concept immediate and tangible.
Absenteeism
The critical pain point affecting all factories is absenteeism — and in most cases it is avoidable or at least manageable. Methods taught operators the different types of absenteeism and how to inform leave in advance.